Table of Contents
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Turn to the Expertg
Installation
Instructions
EQUIPMENT
OPERATION
HAZARD
OAT
sensor
must
be
field installed.
See
Accessory
Installation for more details.
EQUIPMENT
OPERATION
HAZARD
This Infinity
TM
unit is designed for use with an Infinity User
Interface.
NOTE:
Read the entire instruction manual before starting the
installation.
TABLE
OF CONTENTS
PAGE
.........................
2
...................................
2
.................
2-12
..................................
2
Identify Unit ....................................
2
Inspect Shipment .................................
2
...............................
2
Roof Curb ......................................
2
Slab Mount .....................................
2
..................................
2
Provide Clearances .................................
7
Rig and Place Unit .................................
7
......................................
8
Introduction .....................................
8
Use of Rigging Bracket ............................
8
Select and Install Ductwork ...........................
8
Converting Horizontal Discharge Units to Downflow
(Vertical) Discharge Units ..........................
9
.....................
10
Install Flue Hood ..................................
10
.................................
10
........................
11
........................
11
Routing Power Leads Into Unit .....................
12
...........
12
.....................
12
............................
12
Special Procedures for 208-v Operation ..............
12
...................................
15
START-UP .....................................
15-26
...................
15
..........................
20-24
Check for Refrigerant Leaks .........................
25
..............................
25
......
25
Checking and Adjusting Refrigerant Charge ...........
25
A05307
Fig. 1 - Unit 48XL
..............................
26
No Charge .....................................
26
Low Charge Cooling .............................
26
To Use Cooling Charging Charts ....................
26
................................
28-30
Air Filter ........................................
28
Indoor Fan and Motor ..............................
28
Inducer Blower ...................................
28
Limit Switch .....................................
28
Burner Ignition ...................................
28
....................................
28
Inducer Pressure Switch ............................
28
29
Outdoor Fan .....................................
29
Electrical Controls and Wiring .......................
29
Refrigerant Circuit .................................
29
...................................
29
Pressure Switches .................................
29
............................
28
Switches ............................
29
30
Refrigerant System ................................
30
....................................
30
Compressor Oil .................................
30
30
Filter Drier ..........................
30
Puron (R-410A) Refrigerant Charging ...............
30
...........................
30-31
FINAL CHECKS ...................................
32
........................
32
............................
36
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Table of Contents
Troubleshooting
Related Manuals for Carrier Infinity 48XL
Summary of Contents for Carrier Infinity 48XL
-
Page 1: Table Of Contents
15-26 Puron (R-410A) Refrigerant Charging ... TROUBLESHOOTING 20-24 FINAL CHECKS ... CARE AND MAINTENANCE START-UP CHECKLIST ® Turn to the Expertg Fig. 1 - Unit 48XL Emergency Cooling/Heating Mode .. 26 Switch Switches ... Filter Drier ... A05307 28-30 30-31... -
Page 2: Safety Considerations
R-22 systems. equipment or components on Puron (R-410A) Ensure service equipment is rated for Puron (R-410A). INTRODUCTION The 48XL packaged unit is a fully self-contained Category I gas heating/electric air conditioner installation (See Fig. Standard units... - Page 3 ,,Screw.__._ (NOTE -_'l *Gasketing r_ j Wood Ill_l Flashing field supplied JJU_ilt"_ Ro°f curb* II_::i!ll/I# Insulation Roofing material supphed) field supplied-- ll_ii![l /l_!_i:ll II_ Duotwork _ill I[ field supplied/ Roof Curb for Small Cabinet Note A: When unit mounting screw is used, retainer bracket must...
- Page 4 TOP VIEW 798 6 :3:44] FII{L:} _TR_ ¸ _ 8ER,qSE PORIS //'/ ER_IN OUTLET--" [285] _851 [52 72] LEFT SIDE VIEW FRONTVIEW ELEGTRIG_L INIT CHARACTERISTICS 208'230 48XL024¢140 208,230 ,SXLO2,1G#I _SXLU30040 2GS,P30 48XL03_060 CORNER_EIEHT LBS O24040 85/58 85,38 0_4060 86¸¸¸¸39 0 86¸¸¸39 e 8O¸¸¸¸36¸5 0300,!O...
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Page 5: Top View
$090 (42941 SERVICE PORT FULL LOUVER '.yl DRAIN 19,010,75] N,PT X 220[O.BT] DEEP £12.951 1_23.I 144221 LEFT SIDEVIEW TOP VIEW G;%_! [4 611 286{113) FULL LOUVER ¢ 22210881 CONTROL ENTRY 362,9 [14,29} [1.681 COMPRESSOR, BLOWER, ELECTRIC HEAT _ RICAL ACCESS C284) ]2263 [48,28]... - Page 6 Reset (Auto) LOSS-OF-CHARGE LOW- PRESSURE SWITCH (Liquid Line) (psig) Cut-out Reset (auto) RETURN-AIR FILTERS Throwaway (in.)€ (mm) Continued next page. Table I - Physical Data - Unit 48XL 024060 030040 030060 2-1/2 2-1/2 60,000 40,000 60,000 2-Stage Scroll 10.1 11.3 11.3...
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Page 7: Provide Clearances
4 in. (102 above the highest runoff levels. Do not use unit if it has been Table 1--Physical Data (Con't) - Unit 48XL 048090 048115 048130 90,000 115,000 130,000 2-Stage 15.3 15.3 15.3 4Ton 4Ton 4Ton... -
Page 8: Inspection
INSPECTION Prior to initial use, and at monthly intervals, and straps should be visually inspected for any damage, of wear, structural deformation, or cracks. should be paid to excessive wear at hoist hooking support areas. Brackets or straps showing any kind of wear in these areas must not be used and should be discarded. -
Page 9: Access Panel
SEE DETAIL CABINET MODEL Small 48XL-024 Small 48XL-030 48XL-036 48XL-042 Large 48XL-048 48XL-060 NOTE: See dimensional drawing for corner weight distribution. weights shown on drawing are based on unit-only include packaging. IMPORTANT: Use flexible connectors between unit to prevent transmission of vibration. -
Page 10: Provide For Condensate Disposal
Supply Duct Cover Fig. 8 - 48XL with Duct Covers Provide for Condensate Disposal NOTE: Ensure that condensate-water disposal with local codes, restrictions, and practices. The units dispose of condensate through a 3/4 -in. fitting that exits on the compressor end of the unit. -
Page 11: Fire Or Explosion
NIPPLE Fig. 10 - Sediment Trap 7. Pressure test all gas piping in accordance national plumbing and gas codes before to unit. NOTE: Pressure test the gas supply system piping is connected to the gas valve. The supply disconnected from the gas valve during the testing... -
Page 12: Routing Power Leads Into Unit
NOMINAL INTERNAL IRON PIPE DIAMETER SIZE (IN.) (IN.) (3.0) (6.1) .622 .824 1.049 1 - 1/4 1.380 1400 1 - 1/2 1.610 2100 1460 *Capacity of pipe in cu ft of gas per hr for gas pressure of 0.5 psig or less. Pressure drop of 0.5-IN. NFPA 54/ANSI Z223,1. - Page 13 COVER FROM LINE Fig. 11 - Typical Installation GROUND SCREW (IN SPLICE BOX) GROUND LEAD SINGLE-PHASE CONNECTIONS TO DISCONNECT PER NEC L2 ... NOTE: Use copper wire only. LEGEND NEC - National Electrical Code Field Wiring Splice Connections Fig. 12 - Line Power Connections USER INTERFACE...
- Page 14 HP/AC Board Furnac6 Board Fig. 13 - Control User infinity Furnace interface Board Factory Wiring Fig. 14 - Control Voltage Wiring Plate infinity HP/AC Board Outdoor Air Thermistor (Supplied with [U) FIELD CONNECTION REQUIRED (BLACK WIRES) a_Outdeor Coil Thermistor FACTORY CONNECTED FACTORY WIRES PROVIDED FOR FIELD CONNECTION OF UTiLiTY CURTAILMENT...
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Page 15: Pre-Start-Up
PRE-START-UP FIRE, EXPLOSION, ELECTRICAL HAZARD Failure to follow this warning could result iniury or death and/or property damage. 1. Follow recognized safety practices and wear goggles when checking or servicing refrigerant 2. Do not operate compressor or provide any electric power to unit unless compressor ternfinal... -
Page 16: Status Led
emergency heating or cooling operation thermostat and the terminal strip connections on the two control boards (See Non-Communicating Emergency Mode) and will display Status Code 16, System Communication Fault, on amber STATUS LED. No further troubleshooting information will be available at UI until communications re-established. - Page 17 CONNECTION WIRING DIAGRAM DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWERBEFORE SERVICING FIELD SUPPLY UNIT COMPONENT ARRANGEMENT 208,_3o 60HZ,IPH SECTIO_ OUTDOOR _° LEGEND _F[ELD SPLICE _° • SPLICE FACTORY WIRING FIEL@ COnTrOL _IRI_G FIEL@ POWE_ WIRING REMOTE SPARKER CONTROL CQNT CONTACTOR CAPACITOR COMP COMPRESSOR MOTOR...
- Page 18 CONNECTION WIRING DIA6RAM DANGER: ELECTRICAL SHOCK HAZARD DISCONNECT POWERBEFORE SERVICING FIELD SUPPLY UN]T COMPONENT ARRANGEMENT 208/230 OUTDOOR FA,, 60HE, SECTIO_ SECTIOn, SECTION ICCH I GAS SECTIO_ FZELD SPL]CE LEGEND SPL]CE FACTORY WIRING FIELD CONTROL WIRING FIELD POWER WIRING REMOTE SPARKER CONTROL CONT CONTACTOR...
- Page 19 © °° UTILITY RELAY UTILITY SIGNAL OPEN RELAY * SUPPLIED BY UTILITY PROVIDER STATUS CODE 21 - GAS HEATING LOCKOUT Control will NOT auto reset. Check for mis-wired defective control (valve relay). STATUS CODE ABNORMAL SIGNAL Flame is proved while gas valve is de-energized.
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Page 20: Sequence Of Operation
This is because on power-up, the unit control the difference between an open sensor installed. Sequence of Operation 48XL packaged unit is designed communicating This unit will respond provided by a common thermostat except under certain... - Page 21 Table 3 - Air Rated Heating Input (Btu/hr) Unit High Stage Low Stage 48XL(-,N)024040 40,000 26,000 48XL(-,N)030040 48XL(-,N)030060 48XL(-,N)036060 60,000 39,000 48XL(-,N)042060 48XL(-,N)036090 48XL(-,N)042090 48XL(-,N)048090 90,000 58,500 48XL(-,N)060090 48XL(-,N)048115 115,000 75,000 48XL(-,N)060115 48XL(-,N)048130 130,000 84,500 48XL(-,N)060130 Airflow delivery values for external static pressure values of up to 1 IN. W.C.
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Page 22: Fire Hazard
INFINITY CONTROLLED LOW AMBIENT NOTE: When this unit is operating below temperature, provisions must be made for low ambient This unit is capable ambient cooling (-18°C).ONLY when using the Infinity control. is not required, and the outdoor fan motor replaced Infinity controlled ambient... -
Page 23: Carbon Monoxide Poisoning
CARBON MONOXIDE POISONING HAZARD Failure t o follow this warning could result iniury and/or death. If the manifold pressure and/or gas rate adjusted on HI and LO stages, excess carbon be produced. FIRE AND UNIT DAMAGE HAZARD Failure to follow this warning could result... - Page 24 a.129 sec. to complete one revolution b. 3600/129 = 27.9 c. 27.9 x 2 = 55.8 ft3 of gas flow/hr. d. 55.8 x 1050 = 58,590 Btuh input. In this example, the nonfinal input rate for low Btu/hr, so the low stage manifold pressure is correctly If the measured...
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Page 25: Burner Flame
BURNER Fig. 21 - Monoport Burner LIMIT SWITCHES Normally closed limit switch (LS) completes Should leaving-air temperature rise allowable temperature, limit switch opens circuit "breaks." interruption in the control closes the gas valve and stops gas flow to the burners The blower motor continues... -
Page 26: Refrigerant Charge
MODE: This mode of operation has failed or is otherwise techniques. After amount of refrigerant established with standard thermostat control of the 48XL control with until the connectors from charging charts color-coded, insulated are based on charging make the connections operating conditions. - Page 27 Standard 4=Wire Thermostat Fig. 22 - Non-Communicating Required Subcooling °F (°C) Outdoor Ambient Temperature Model Size 15.5(8.6) 15.6(8.7)15.7(8.7)15.8(8.8)15.9(8.9) 16.8(93) 16,4(9.I) I6.2(9) 14(7.7) 13.9(7.7) 13.9(7.7) 19.2( 10.7 ) 19.1 ( 10.6 ) 19.1( 10.6 ) 18.9 ( 10.5) 18.7( 10.4 ) 21(11.6) 20.8(11.5) 20,7(11.5)
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Page 28: Maintenance
MAINTENANCE To ensure continuing high performance, possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This packaged be inspected at least once each year by a qualified service person. To troubleshoot unit, refer to Table 10, Troubleshooting Chart. NOTE TO EQUIPMENT OWNER: Consult your local dealer... -
Page 29: Electrical Shock Hazard
ELECTRICALSHOCK HAZARD Failure t o follow this warning could result injury or death. Disconnect electrical power cleaning and lubricating the blower motor and wheel. Outdoor Coil, Indoor Coil, and Condensate Drain Inspect the condenser coil, evaporator coil, and condensate pan at least once each year. The coils are easily cleaned when dry;... -
Page 30: Copeland Scroll Compressor (Puron Cr) Refrigerant)
Mobil 3MA POE oil. This is the only oil allowed for oil recharge. Refrigerant System This step covers the refrigerant system of the 48XL, including the compressor oil needed, servicing systems on roofs containing synthetic materials, the filter drier, and refrigerant charging. -
Page 31: Troubleshooting
- Defrost operation - Low ambient cooling - Crankcase heater operation - Compressor external protection - Pressure switch monitoring (refrigerant) - Time delays FURNACE BOARD The furnace board controls the following functions: - Indoor blower operation - Gas valve - Inducer motor - Remote sparker... -
Page 32: Final Checks
THERMISTOR CURVE 80- k---- 4------ 4----- _------ 4-------I 7o- -'_-- q------ I----- _------ T------I ... 6o- _ _X__ J ._ _ _ .I_ _ _ __ _ _ J_ _ _ _I ... 50 ... '_------ 1----- _------ 1-------I ... 40- - /_.__ l______/___l... -
Page 33: Air Conditioner
AIR CONDITIONER REFRIGERATION Puron refrigerant operates at 50-70 percent designed to operate with Puron. Puron refrigerant • Puron refrigerant cylinders manufactured prior to March 1, 1999, have a dip tube that allows liquid to flow out of cylinder in upright position. - Page 34 SYMPTOM Compressor and outdoor fan will not start Compressor will not start but condenser runs Compressor cycles (other than normally sat- isfying) cooling/heating calls Compressor operates continuously Excessive head pressure Head pressure too low Excessive suction pressure Suction pressure too low IFM does not run IFM operation is intermittent...
- Page 35 Table lO--Troubleshooting SYMPTOM Burners will not ignite Inadequate heating Poor flame characteristics Chart Con't-Gas Furnace CAUSE Water in gas line No power to unit No 24-v power supply to control circuit Mis-wired or loose connections Misaligned spark electrodes No gas at main burners Inducer pressure switch not closing Dirty air filter Gas input to unit too low...
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Page 36: Start-Up Checklist
( ) VERIFY THAT OUTDOOR AIR THERMISTOR *Measured at suction inlet to compressor 1-Measured at liquid line leaving condenser. Copyright 2008 Carrier Corp. • 7310 W. Morris St. • Indianapolis, Manufacturer reserves the right to change, at any time, specifications...
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